Plaster panel and method of using same

ABSTRACT

A plaster panel and a method of using it is disclosed, wherein the plaster panel includes a slab of cementitious composition including a mixture of sizes of cut expanded polystyrene, a quantity of monofilament fiber, and at least one binding agent. At least one layer of a mesh is provided, wherein the resulting panel is light in weight, flexible and strong. Similar panels may be affixed to a building frame by suitable fasteners such as nails or screws, while causing little or no fracturing of the panel.

FIELD OF THE INVENTION

The present invention relates to a plaster panel and a method of using the plaster panel. The present invention more particularly relates to such a plaster panel and method used preferably in building construction as a foundation for or in place of stucco, plaster, tile, siding, exterior insulation finish systems, direct applied exterior systems, interior systems, or others.

BACKGROUND ART

This section describes the background of the disclosed embodiment of the present invention. There is no intention, either express or implied, that the background art discussed in this section legally constitutes prior art.

There have been many different types and kinds of plaster panels used in building construction. For example, reference may be made to the following U.S. Pat. Nos. 4,298,413; 4,450,022; 4,504,335; 5,221,386; 5,352,390; 5,580,378; 6,187,409; 6,995,098; 7,182,589; 7,255,738; and 7,276,551; as well as Canadian patent 969,700.

Current methods for applying exterior plaster to many commercial buildings may take an undesirably long period of time such as approximately 12 to 13 days under certain circumstances. After application, the plaster may cure for up to 30 days before fractures such as cracks begin to appear. Then, additional plaster may be required to be applied to patch the cracks that formed during the curing phase. In some situations, several exterior coatings may be required to properly finish the wall. Also, when plaster is applied to a long wall, it may be difficult and time consuming to generate a smooth continuous planar surface over the entire length of the wall.

Additionally, during the application of the plaster, there can be waste by draining off, referred to as “spillage,” of the walls excess amounts of the plaster matter. Such spillage is a waste of the plaster material, and may create environmental problems under certain circumstances.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of this invention and the manner of attaining them will become apparent, and the invention itself will be best understood by reference to the following description of certain embodiments of the invention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a partially broken away elevational face view of the plaster panel, which is constructed in accordance with an embodiment of the present invention;

FIG. 2 is an enlarged partially broken away top edge plan view of the plaster panel of FIG. 1, shown in an enlarged scale for illustration purposes;

FIG. 3 is an enlarged, broken away diagrammatic sectional view of a portion of the plaster panel of FIG. 1;

FIG. 4 is a broken away diagrammatic top plan view of the panel of FIG. 1 together with other like plaster panels in the process of being assembled and installed to form a portion of a wall;

FIG. 5 is a partially broken away elevational face view of a plaster panel, which is constructed in accordance with another embodiment of the present invention;

FIG. 6 is an enlarged partially broken away top edge plan view of the plaster panel of FIG. 5, shown in an enlarged scale for illustration purposes;

FIG. 7 is an enlarged broken away diagrammatic sectional view of a portion of the plaster panel of FIG. 5;

FIG. 8 is a top plan view of the panel of FIG. 5 together with other like panels in the process of being assembled and installed to form a portion of a wall;

FIG. 9 is a broken away diagrammatic sectional pictorial view of a plaster panel, which is constructed in accordance with a further embodiment of the present invention; and

FIG. 10 is a diagrammatic partially broken away elevational face view of a series of like plaster panels constructed according to a further embodiment of the present invention and assembled to form a portion of a wall.

CERTAIN EMBODIMENTS OF THE INVENTION

Certain embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, these embodiments of the invention may be in many different forms and thus the invention should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided as illustrative examples only so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

According to certain disclosed embodiments of the present invention, there is provided plaster panels and methods of using them to construct a wall of a building in a relatively faster, easier, more efficient, and more precise manner for either interior or exterior walls. The plaster panels are lighter in weight and structurally strong. Such panels can be fixed in place to a building frame by suitable fasteners such as nails or screws, while causing little or no fracturing of the panel.

A plaster panel and a method of using it is disclosed, wherein the plaster panel includes a slab of cementitious composition including a mixture of sizes of cut expanded polystyrene, a quantity of monofilament fiber, and at least one binding agent. At least one layer of a mesh is provided, wherein the resulting panel is light in weight, flexible and strong. Similar panels may be affixed to a building frame by suitable fasteners such as nails or screws, with causing little or no fracturing of the panel.

Typically, the mixture of cut expanded polystyrene may be comprised of cut expanded polystyrene pieces having an average size of about 2286 microns ( 3/32 inch). More typically, the mixture of the cut expanded polystyrene pieces may be comprised of about 50% cut expanded polystyrene pieces having a size of about 3175 microns (⅛ inch) and about 50% cut expanded polystyrene pieces having a size of about 6350 microns (¼ inch). The cut expanded polystyrene may be cut from expanded polystyrene with a foam density of a suitable weight such, for example, as about one pound per cubic foot.

The layer of mesh may be a sheet of mesh material which is imbedded within the interior of the cementitious slab. Alternatively, a sheet of mesh material may be disposed on an outer surface of the cementitious slab, and another sheet of mesh material may be disposed on an opposite outer surface of the cementitious slab.

According to certain embodiments of the invention, a plaster panel is disclosed which may include the following:

-   -   at least one layer of mesh;     -   about 1.5% by weight cut expanded polystyrene;     -   about 0.5% by weight polypropylene monofilament fiber;     -   about 35% by weight sand;     -   about 35% by weight cement;     -   about 7% by weight acrylic binding agent;     -   about 0.1% by weight foam control agent; and     -   a balance of water;     -   wherein the plaster panel is light in weight, flexible, strong,         and substantially impervious to moisture penetration.

The mesh may be a reinforcing alkali resistive mesh such as a fiberglass mesh. The plaster panel may be comprised of a single layer of mesh or, for example, two layers of mesh which substantially encase the plaster panel. Alternatively, the plaster panel may include three layers of mesh, the middle layer of which is embedded within the plaster panel.

The polypropylene monofilament fiber typically may have a specific gravity of 0.91. Typically the sand may have a 60 grit construction grade sand and the cement may be a type 2 Portland cement. The acrylic binding agent may be liquid acrylic or aqueous acrylic emulsion.

The embodiments of the plaster panel may receive fasteners such as nails and screws directly with little or no fracturing such as cracking of the plaster panel for certain applications.

Typically, the plaster panel may have opposite side edges which are complementary such as side edges which are interfitting or interconnecting such as an overlapping arrangement. More typically, the plaster panel may have opposite side edges which are beveled. Such a construction of the plaster panel of embodiments of the invention enable like panels to be installed in a smooth continuous manner in a variety of dispositions such as vertical or horizontal.

The plaster panel typically may have dimensions of about four feet in width by about eight feet in length with a thickness of between about ¼ inch and about ⅞ inch. The presently preferred thickness is ½ inch. However, other dimensions may also be employed for other applications.

The surface of the plaster panel may exhibit a rough stipple finish, a smooth slick finish, or other.

According to another embodiment of the invention, a method of applying two or more plaster panels with complementary opposite side edges to form a wall of a building may include the following steps:

-   -   positioning on the frame of the wall a first plaster panel         having interfitting opposite side edges;     -   attaching the first plaster panel to the wall using suitable         fasteners such as screws or nails;     -   positioning on the frame of the wall a second plaster panel         having interfitting opposite side edges, wherein the second         plaster panel is disposed adjacent to the first plaster panel;     -   interfitting the first plaster panel and second plaster panel         along the adjacent side edges creating a flush seam;     -   attaching the second plaster panel to the wall using suitable         fasteners such as screws or nails,     -   taping the flush seam of the first and second plaster panels         with mesh such as a fiberglass mesh; and     -   coating the plaster panels with a cementitious composition.

One or more additional plaster panels with interfitting edges may also be attached to complete the wall.

According to yet another embodiment of the invention, a method of applying two or more plaster panels with complementary edges to a wall of a building may include the following steps:

-   -   positioning on the frame of the wall a first plaster panel         having beveled opposite side edges;     -   attaching the first plaster panel to the wall using suitable         fasteners such as screws or nails;     -   positioning on the frame of the wall a second plaster panel         having beveled opposite side edges, wherein the second plaster         panel is adjacent to the first plaster panel creating a seam         integration cavity formed by adjacent beveled side edges of the         first and second panels;     -   attaching the second plaster panel to the wall using suitable         fasteners such as screws or nails;     -   coating the plaster panels with a cementitious composition or         other finishing material, and filling the seam integration         cavity therewith to help provide a desired finish to the         resulting wall; and     -   taping the seam integration cavity of the first and second         plaster panels with mesh such as a fiberglass mesh.

One or more additional plaster panels with beveled edges may also be attached. In this manner, a generally smooth flat wall may be constructed in a convenient manner, with little or substantially no post cure fracturing such as cracking.

Referring now to FIGS. 1 through 4 of the drawings, there is shown a plaster panel 10, which is constructed in accordance with an embodiment of the present invention. FIG. 1 depicts the plaster panel 10 with complementary side edges 12 and 14. As more clearly seen in FIGS. 1 and 2 of the drawings, the side edges 12 and 14 are interlocking and include notches 16 and 18 respectively, to provide an overlapping seam.

The depth of the notch such as the depth of the notch 16 is preferably approximately equal to one half of the thickness of the panel 10. The notch such as the notch 16 may be of a sufficient length, such as about 1¼ inches, to provide a secure overlapping flush seam with an adjoining panel.

As best seen in FIG. 3 of the drawings, the plaster panel 10 includes a centrally disposed cementitious slab 21, which is generally rectangular in configuration. A pair of layers of mesh sheets 23 and 25 such as sheets of fiberglass mesh are disposed on the outside surfaces of the slab 21 to substantially surround it.

The mesh sheet 25 overlies one face of the slab 21 and overlaps both notches 16 and 18 and the respective side edges 12 and 14, and terminates on the opposite face of the slab 12, at 26 and 28, respectively. The mesh sheet 23 overlies the opposite face of the slab 21 and the terminating edges 26 and 28, as well as the notches 16 and 18.

As best seen in FIG. 4 of the drawings, the plaster panel 10 can be affixed by suitable fasteners such as screws or nails to a building frame (not shown) to form a wall 27. Like plaster panels 29, 32 and others (not shown) are fitted together at their complementary side edges to form a continuous wall such as a planar wall, or other desired configurations. Fiberglass strips 34 and 36 are used to cover the joints between adjacent plaster panels overlying the complementary side edges of the adjacent panels. A cementitious coating 38 can then be applied to the outer surface of the plaster panels to help provide a finish coat. The cementitious coating 38 may be composed of a conventional embedding or filling coat such as a conventional base coat.

An outer finish coating 39 may be applied to the cementitious coating 38. The coating 39 may be a conventional color coating, paint, or other exterior coating.

Referring now to FIGS. 5 and 6 of the drawings, there is shown a plaster panel 42, which is also constructed in accordance with an embodiment of the invention. The plaster panel 42 is generally rectangular in configuration, but may also assume various different sizes and shapes. The panel 42 has a pair of longitudinal complementary side edges 44 and 46 in the form of chamfered or beveled configurations. In this manner, the complementary beveled side edges 44 and 46 enable them to cooperate with similar complementary edges of like panels.

The panel 42 is adapted to be attached to a building frame (not shown) by using suitable fasteners such as screws or nails.

Referring now to FIG. 7, the plaster panel 42 includes a cementitious slab 48, which is composed of the cementitious composition including a mixture of sizes of cut expanded polystyrene, a quantity of monofilament fiber and a binding agent, similar to the cementitious slab 21.

The plaster panel 42 includes a center layer of a mesh sheet embedded within the cementitious slab 48 to provide added strength to the panel 42. A pair of outer layers of sheets 55 and 57 of mesh are disposed on the outer surfaces of the slab 48. The layer 57 of mesh overlies one face of the slab 48 and has wraparound side portions 59 and 62 to engage the side edges and the beveled edges of the slab 48 forming the beveled edges 44 and 46 of the resulting panel 42. The outer layer 55 of mesh overlies the opposite face of the slab 48 for engaging and overlying the opposite terminal edges 51 and 56 of the layer 57 terminating on the opposite face. In this manner, the outer layers 55 and 57 of mesh substantially surround and strengthen the resulting panel 42 so as to resist various loading such as from wind blasts.

As shown in FIG. 8, a wall 68 may be assembled to a building frame (not shown) by suitable fasteners such as nails or screws by employing the plaster panel 42 and other like plaster panels such as panels 68 and 73 arranged adjacent to one another to form a substantially planar wall or other wall configurations.

Beveled side edges such as the beveled side edge 44 of the panel 42 mate with adjacent beveled side edges such as a beveled side edge 74 of the panel 71, to form a V-shaped seam integration cavity such as cavities 76 and 78. Suitable strips or tape, such as fiberglass strips 75 and 77, are used to tape over the V-shaped integration cavities such as the cavities 76 and 78 respectively.

After taping the cavities, a cementitious coating 79 is then applied over the entire wall 68 and thereby forming V-shaped projections such as the projections 80 and 81 to fill the seam integration cavities such as the cavities 76 and 78 respectively.

The cementitious coating 79 may be composed of the same conventional embedding or filling coat such as a base coat, as the coating 39 as previously described.

Referring now to FIG. 9, there is shown a plaster panel 82 which is also constructed in accordance with yet another embodiment of the present invention. Plaster panel 82 is similar to the plaster panel 10 of FIG. 1, except that the plaster panel 82 includes a cementitious slab 86, which includes a centrally disposed layer 88 of mesh embedded within the slab 86.

Referring now to FIG. 10, there is shown a plaster wall 89, which is a presently preferred arrangement of plaster panels, and which is composed of a series of plaster panels such as plaster panels 91, 93 and 94 arranged in a certain configuration. Each one of the plaster panels is similar to either the plaster panel 10 or the plaster panel 42 and are affixed to a building frame (not shown). Each plaster panel is generally rectangular in configuration and is preferably 4 feet in width by 8 feet in length.

Each one of the plaster panels such as the plaster panels 91 and 93 are arranged with their lengths disposed horizontally and are arranged in staggered rows. For example, the panels 91 and 93 are disposed adjacent to one another with their long dimensions disposed horizontally. The panel 94 is disposed in an adjacent row above the panels 91 and 93 in a staggered configuration. The panel 94 is disposed with its longitudinal axis in a horizontal disposition centrally aligned with the abutting edges of the panels 91 and 93.

The embodiments of the plaster panels provide environmental safeguards when compared to conventional stucco walls. Traditionally, stucco walls have been applied in several layers, with a substantial amount of spillage of the stucco material during application, which may be washed into the flood control system. The present embodiments of the method of installing the embodiments of the plaster panels may not require several applications of stucco, and thus, they generally do not exhibit undesirable spillage of the stucco material as any spillage may be minimized or greatly reduced.

Additionally, cement presently is in short supply, and therefore it is highly desirable to conserve cement consumption. By eliminating several applications of stucco for certain conventional installations, the present embodiments of the method of installing the inventive plaster panel may result in a decreased consumption of cement. Furthermore, the embodiments of the plaster panel of the present invention may use less sand and gravel than traditional stucco walls for certain applications, as the inventive embodiments of the plaster panels include recovered expanded polystyrene beads that have been cut into fragments and serve as a low density aggregate.

The plaster panel embodiments may be installed quickly and efficiently. Traditional methods of applying stucco to the exterior walls of a building such as a residential house, have under certain circumstances required approximately 13-15 days of spraying, followed by curing time for certain installations. Often fracturing such as cracking would occur in certain applications during the curing time thereby necessitating additional stucco layers to be applied. The plaster panels of the embodiments of the present invention essentially eliminate or at least greatly reduce excessive installation time for at least certain applications.

It should be understood that when words such as “about,” “approximately,” “substantially” or the like are used herein, a tolerance of plus or minus 20 percent may be employed.

Although the invention has been described with reference to the above examples, it will be understood that many modifications and variations are contemplated within the true spirit and scope of the embodiments of the invention as disclosed herein. Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention shall not be limited to the specific embodiments disclosed and that modifications and other embodiments are intended and contemplated to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

1. A plaster panel, comprising: a slab of a cementitious composition; the cementitious composition including a mixture of sizes of cut expanded polystyrene, a quantity of monofilament fiber and at least one binding agent; and at least one layer of a mesh; wherein the plaster panel is light in weight, flexible and strong.
 2. A plaster panel of claim 1, further including: at least two layers of mesh.
 3. A plaster panel of claim 2, wherein the cementitious composition including: about 1.5% by weight mixture of cut expanded polystyrene; about 0.5% by weight polypropylene monofilament fiber; about 35% by weight sand; about 35% by weight cement; about 7% by weight acrylic binding agent; about 0.1% by weight foam control agent; and a balance of water; wherein the plaster panel is substantially impervious to moisture penetration and able to receive fasteners with substantially no fracturing of the cementitious composition.
 4. The plaster panel of claim 1, wherein the mesh is a reinforcing alkali resistive mesh.
 5. The plaster panel of claim 2, wherein two layers of mesh substantially encase the plaster panel.
 6. The plaster panel of claim 5, wherein the panel is further includes a third layer of mesh which is embedded within the plaster panel.
 7. The plaster panel of claim 1, wherein the cut expanded polystyrene includes cut expanded polystyrene pieces having an average size of about 2286 microns.
 8. The plaster panel of claim 1, wherein the cut expanded polystyrene includes about 50% cut expanded polystyrene pieces having a size of about 3175 microns and about 50% cut expanded polystyrene pieces having a size of about 6350 microns.
 9. The plaster panel of claim 1, wherein the cut expanded polystyrene is cut from expanded polystyrene with a foam density of about one pound per cubic Toot.
 10. The plaster panel of claim 3, wherein the polypropylene monofilament fiber has a specific gravity of 0.91.
 11. The plaster panel of claim 3, wherein the sand is a 60 grit construction grade sand.
 12. The plaster panel of claim 3, wherein the cement is type 2 Portland cement.
 13. The plaster panel of claim 3, wherein the acrylic binding agent is liquid acrylic or aqueous acrylic emulsion.
 14. The plaster panel of claim 1, wherein the edges of the plaster panel are interfitting.
 15. The plaster panel of claim 1, wherein the edges of the plaster panel are beveled.
 16. The plaster panel of claim 1, wherein the board has dimensions of about four feet in width by about eight feet in length by about one-half inch in thickness.
 17. The plaster panel of claim 1, wherein the plaster panel has a surface exhibiting a rough stipple finish.
 18. The plaster panel of claim 1, wherein the plaster panel has a surface exhibiting a smooth slick finish.
 19. A method of applying two or more plaster panels with complementary opposite edges to a wall of a building, comprising: positioning a first plaster panel on the frame of the wall; attaching the first plaster panel to the wall using fastening devices; positioning a second plaster panel on the frame of the wall, wherein the second plaster panel is disposed adjacent to the first plaster panel; interfitting the first plaster panel and second plaster panel along the adjacent edges creating a flush overlapping seam; attaching the second plaster panel to the wall using fastening devices; taping the flush overlapping seam of the first and second plaster panel with fiberglass mesh; and coating the plaster panels with a cementitious composition.
 20. The method of claim 18, wherein one or more additional plaster panels with interfitting edges are attached.
 21. A method of applying two or more plaster panels with beveled edges to a wall of a building, comprising: positioning a first plaster panel on the frame of the wall; attaching the first plaster panel to the wall using fastening devices; positioning a second plaster panel on the frame of the wall, wherein the second plaster panel is disposed adjacent to the first plaster panel creating a seam integration cavity; attaching the second plaster panel to the wall using fastening devices; taping the seam integration cavity of the first and second plaster panel with fiberglass mesh; and coating the plaster panels with a cementitious composition.
 22. The method of claim 20, wherein one or more additional plaster panels with beveled edges are attached. 